106675-4610

ZEXEL Ass'y No.

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
Edition date

P
P

P
P
P
P

Page 1

106675-4610
F 019 Z20 142
D2366T
DPICO
12.10.06 (5)

1 Adjustment conditions
CAT Designation
Test oil

07.01.15 16:00:54

ZEXEL test values diesel fuel-injection equipment

Test oil temperature

Nozzle and nozzle holder
Bosch type code
Nozzle
Bosch type code
Nozzle holder
Bosch type code
Opening pressure
Opening pressure
Injection pipe
Overflow valve
Overflow valve opening pressure
Overflow valve opening pressure
Tester oil delivery pressure
Tester oil delivery pressure
Direction of rotation (viewed from drive side)

Unit

Set value
min.
ISO4113 or {SAEJ96
7d}

1404 Test oil

degC

max.

40
40
105780-8140
EF8511/9A
105780-0000
DN12SD12T
105780-2080
EF8511/9
MPa
17.2
kgf/cm2
175
mm
8-3-600
Outer diameter - inner diameter - length (mm)
131424-4420
kPa
157
123
kgf/cm2
1.6
1.25
kPa
157
157
kgf/cm2
1.6
1.6
R
Right

45

Unit

min.

max.

1-5-3-6-2-4
4.3
NO.1

4.25

4.35

60

59.5

60.5

120

119.5

120.5

180

179.5

180.5

240

239.5

240.5

300

299.5

300.5

Set value
A
10.8
1100
145
0
*
*
80
600

min.

max.

1100
143
-2

1100
147
2

Set value
B
4.9+-0.5
400
15.5
0
*
0
0

min.

max.

400
14
-15

400
17
15

0
0

0
0

Actual values

OT

Actual values

OT

Actual values

OT

Actual values

OT

191
1.95
157
1.6

2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation
P
Direction of rotation (viewed from drive side)

Set value
R

Right
P
S
P

Injection order
Pre-stroke
Beginning of injection position

Difference between angles 1

Difference between angles 2

Difference between angles 3

Difference between angles 4

Difference between angles 5

2.2 Injection quantity adjustment

CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
Average injection quantity
S
Max. variation between cylinders
P
Basic
P
Fixing the lever
P
Boost pressure
P
Boost pressure
CAT
P
P
P
S
S
P
P
P

Designation
Adjusting point
Rack position
Pump speed
Average injection quantity
Max. variation between cylinders
Fixing the rack
Boost pressure
Boost pressure

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)

mm
Governor side
deg.
Cal 1-5
deg.
Cal 1-3
deg.
Cal 1-6
deg.
Cyl.1-2
deg.
Cal 1-4
Unit

r/min
mm3/st.
%

kPa
mmHg
Unit

r/min
mm3/st.
%
kPa
mmHg

80
600

106675-4610

07.01.15 16:00:54

ZEXEL test values diesel fuel-injection equipment

CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
Average injection quantity
P
Fixing the lever
P
Boost pressure
P
Boost pressure
P
Rack limit
2.3 Governor adjustment
Name

K=7
BCL=1.6+-0.1mm

2.4 Boost compensator adjustment

CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure

Unit

r/min
mm3/st.
kPa
mmHg

min.

max.

100
146

100
156

0
0

0
0

Set value
500
R1-1.6
13.3
100

min.
500

max.
500

11.3
85

15.3
115

Set value
500
R1-1
32
240

min.
500

max.
500

28
210

36
270

Set value
500
R1(10.8)
66.7

min.
500

max.
500

66.7

66.7

500

500

500

Actual values

OT

Actual values

OT

Actual values

OT

Actual values

OT

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Deliver without the torque control spring operating.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Set idle sub-spring
Unit
r/min
kPa
mmHg

CAT
P
P
S
S

Designation
Pump speed
Rack position
Boost pressure
Boost pressure

Unit
r/min

CAT
P
P
S

Designation
Pump speed
Rack position
Boost pressure

Unit
r/min

Boost pressure

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)

Set value
E
100
146
*
0
0
*

Page 2

kPa
mmHg

kPa
About
mmHg
About

106675-4610

ZEXEL test values diesel fuel-injection equipment

07.01.15 16:00:54

2.5 Speed control lever angle

Name
a=10deg+-5deg
b=27deg+-5deg

F:Full speed
I:Idle
(1)Stopper bolt setting
2.6 Stop lever angle
Name
a=32deg+-5deg
b=70deg+-5deg

aa=0r/min
bb=1-0.5mm
2.7 Additional device adjustment

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)

N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)

Page 3

106675-4610

ZEXEL test values diesel fuel-injection equipment

07.01.15 16:00:54

Page 4

2.7.1 Additional device 1

Name
TAMPER PROOF

T1=2.5N-m(0.25kgf-m)
T2=2.9~4.4N-m(0.3~0.45kgf-m)

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)

Tamperproofing-equipped boost compensator cover installation procedure

(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified to
rque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to brea
k off the bolt heads.
(Tightening torque T = T2)

106675-4610

ZEXEL test values diesel fuel-injection equipment

07.01.15 16:00:54

2.8 Timing setting

Name
a=(70deg)

(1)Pump vertical direction

(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)(4)-

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)

Page 5